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Maintenance Costs and Advanced Maintenance Techniques in Manufacturing Machinery: Survey and Analysis
1National Institute of Standards and Technology, Gaithersburg, MD, 20899, USA.
International Journal of Prognostics and Health Management
|February 3, 2023
Summary
Investing in advanced maintenance significantly reduces costs. Shifting from reactive to predictive maintenance cuts unplanned downtime by over 18% and defects by 87%, saving billions annually.
Area of Science:
- Industrial Engineering
- Operations Management
- Manufacturing Systems
Background:
- The financial implications of maintenance strategies are not fully understood.
- Inadequate maintenance incurs significant national economic losses.
Purpose of the Study:
- To estimate national maintenance costs and losses.
- To compare the economic impact of reactive, preventive, and predictive maintenance.
Main Methods:
- Data collected from manufacturers.
- Monte Carlo analysis for cost estimation.
- Categorization of respondents based on maintenance strategy reliance.
Main Results:
- Estimated annual maintenance costs/losses: $222.0 billion.
- Companies using predictive/preventive maintenance experienced 52.7% less unplanned downtime and 78.5% fewer defects.
- Predictive maintenance yielded 18.5% less downtime and 87.3% fewer defects compared to preventive maintenance.
Conclusions:
- Transitioning from reactive to advanced maintenance offers substantial economic benefits.
- Predictive maintenance demonstrates superior performance in reducing downtime and defects over preventive maintenance.
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